2016

Cyclone 5 Inner Pipe Replacement

Submitted by:
Kiln Inspection Engineer

Eng. / Mohammad Gamal El Rajy

Under Supervision:
Inspection Section Head

Eng. / Mohammad Ramadan

Eng. /Ashraf Fahmi

Preventive Maintenance Manager

January 04
M.Gamal
[Type the company name]
1/4/2016
 CYCLONE 5 INNER PIPE REPLACEMENT 01/04/2016

Table of content
1.Introduction Page 3

2. Inner pipe inspection strategy Page 3

3. Latest replacement history of the inner pipe Page 4

4. Replacement the inner pipe of Cyclone 5 Page 5

5. Conclusion Page 8

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 CYCLONE 5 INNER PIPE REPLACEMENT 01/04/2016

1. Introduction
The inner pipe of cyclone 5 set has been replaced at the unplanned kiln shutdown on December 2015
according to the inspection which has been executed on February 2015. This report will discuss inspection
basics of inner pipes segments according to FLS instructions which have been committed when inner pipes
of cyclone 5 segments replacement.

2. Inner pipe inspection strategy

First of all its necessary to present a clarification for inner pipe components and it is as follow:

01 Suspension Element

02 Top Element

03 Standard Element

04 Inner Locking Element

05 Outer Locking Element

FLS recommendation is replacing the inner pipe completely when 50% of the original material thickness
(16 mm is the general thickness for the segment plate) has eroded away see Drawing 2.1 and
attachment 1.

From site experience the top element segment (02) is the most part which exposed to wear and the
most critical part where if it fails the inner pipe will fail completely because segments are engaged
together by eye and shoulder design and once segment failed all segments will fall down like domino
plates under hot gases impact, so the life time of inner pipe is determined by the thickness of the top
element segment (02).

The area from inner pipes which faces the hot gases inlet has the maximum wear rate where the impact
of hot gases is the maximum due its velocity, so its normal to find many segments from standard
element (03) have a moderate or good wear rate especially areas away of gases inlet see fig 2.1.

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 CYCLONE 5 INNER PIPE REPLACEMENT 01/04/2016

Inner and outer locking (04), (05) must be free from cracks to ensure good keying between segments to
prevent segments fall down.

Fig 2.1 Drawing2.1

3. Latest replacement history of the inner pipe

Inner pipe segments have been replaced at:
1. October 2011
2. October 2013
3. December 2015

Regarding to the replacement history we can determine the replacement rate which is around every 2 years

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 CYCLONE 5 INNER PIPE REPLACEMENT 01/04/2016

4. Replacement of the inner pipe of Cyclone 5

At Kiln shut down on February 2015

Complete inspection for inner pipe segments has been made by:-

Measuring thickness of top element segment (02) at the area face the hot gases inlet which was
between 8.5 to 10 mm.
Visual inspection of segments for cracks.
Visual inspection of inner and outer locking for wear and cracks.

According to FLS instruction and our inspection -where the measured thickness reaches 50% from the
original thickness 16 mm, we decide that the inner pipe can stand only for 7 or 8 months as maximum to reach
its maximum availability and to be replace at the next shutdown on October 2015.

At Kiln shut down on December 2015

Inner pipe segments have been replaced, and by inspection of the old segment we found that:-

Thickness of top element segments (02) suffering from a severe wear and corrosion where you
can differentiate the worn out thickness easily by the first look comparing with the original
thickness (The thickness reached to 3 to 4.5 mm at the worn-out part) see pic 4.1,2.

Fig 4.1

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 CYCLONE 5 INNER PIPE REPLACEMENT 01/04/2016

Fig 4.2
For first time we found a cracks at the top element segments (02) see pic 4.3,4.

Fig 4.3

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 CYCLONE 5 INNER PIPE REPLACEMENT 01/04/2016

Fig 4.4
We found many cracks at the inner and outer lock see Fig 4.5,.

Fig 4.5

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 CYCLONE 5 INNER PIPE REPLACEMENT 01/04/2016

5. Conclusion

1. The inspection of inner pipe has been done based on FLS company instructions and recommendation.

2. We had to replace the inner pipe set at February 2015 shutdown according to FLS recommendation
where the wear rate reached to 50 % of its thickness, but according to our experience we figured out
that the inner pipe can stand to the next shutdown on October 2015. The next shutdown has been done
on December 2015 that means 2 months after of the estimated date to replace the inner pipe set.

3. We have taken in our consideration when we decided to replace the inner pipe that ensuring the
maximum availability from spare parts (cracks and severe wear) without exposing to failure before the
planned shutdown which achieving the maximum reliability (no unplanned shutdown) for the equipment.

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